Coated textile material and method of making same



Oct- 13, 1 w. R. KEEN El'AL 2,908,013

COATED TEXTILE MATERIAL AND METHOD OF MAKING SAME Filed May 9, 1957 INVENTZORSI' ll fi'dwmflsepk Gig eek 4 BY milmlizlolkaitkelz,

PM d'i'aul ATTORNEYS United States Patent 2,908,013 COATED TEXTILE MATERIAL amnion "ice It is another object of this invention to provide a tufted carpet having a jute woven backing coated with a latex material adapted to retain coloring matter which will harmonize with the color of the pile tufts of said carpet s t .5 and which will enhance .thestability ofthe backing .ma- OF MAKING SAME teri-al of the carpet.

William Rollin Keen, Media, and Edwin Joseph Grajeck, It is still another object of this invention to provide a Malvel'n, Pa a ig O COllillS & ma C 'P I method of making a tufted carpet in which a latex coating 15011, New York 1a corporationof Delaware material is applied to the backing of the carpet prior to I v 10 tufting so that the backing material will not be distorted Apphcatlon May 9, .1957, .Serial No. 658,150 y the p s g of'tufting needles. I

3 Claims. (Cl. 2-2778) Other objectsandadvantages of .theinvention will .be-

come apparent from the following description and the v drawings of which: I

This invention relates to a new .coloring material used Fig. 1 is a perspective view of a piece of jute backing in the backing material of a tufted fabric and to a methmaterial of the type normally used in the 'manufacture 0d of making such a fabric. /Morefparticularly the inof tufted carpets; vention relates to decoratively coated jute woven back- Fig. 2 is a schematic view showing an application of ings usedinoarpets. the colored coating material to the backing material of Carpets have heretofore been made by tufting-textile Fig.1 in accordance with the invention; yarns in a woven jutebacking-material. Such carpets Fig. 3 is an enlarged, partial, side elevation of the were dyed with a coloring material to provide an interbacking material of Fig. 1 following the treatment of csting and decorative appearance. However the jute Fig. 2; backing material does not acceptthe-dyes normally used Fig. 4 is a schematic view showing the tufting and and in the resulting carpet there have been noticeable 2 Shearing of the backing material following the treatment differences in shadebetween the pile tufts and thebackof Fig.2; and ing material. Since the backing materialina tufted fab- Fig. 5 is a par'tialperspective view of the tuftedmateric is normally somewhat-visiblethrough the pile this rial following the operation'of Fig. 4. discrepancy in coloring detracts from the appearance of The backing material 10 illustrated in Fig. l-is typical the .fabric. j of the backing material .presently used in the manufac- It has also been a problem in the manufactureof-tufted ture of tufted carpets. It will be noted that the woven fabrics and particularly carpet materials that the meshes fabric 10 is not regular and uniform and that there are in the backing material are not regular and uniform. substantial variations-in the alignment of the .weft strands Dus to this thetufting -needles.have often distorted the 11 and the warp strands 12 and the positioning of the original strand alignments of the backing material durmeshes. illg the tuftillg Operation thereby disrupting the Q It has been found thatwhen such a backing material Surface .Of thebacking material an attendant :lOSS of i to form a'carp et in the normal mannertwo. probunifqrmity P i resultingprodufig lems arise. The tufting operation results in distortion of It 15 PnmlPa1 P of lnventlon opr a 40 the backing material v10 due to the tufting needles strikdecoratlve colored coating mfuenal to the ing the strands '11 and 12 in different places, and after upper Surface of woven 1M6 P i i for a the backing material 10 is tufted and is dyed to provide tufted carpet WhlCh will harmonize -1n color with the 1 th t b t 31 d t h d tufted pile yarns and will in addition provide stability to co or 6 Ju 8 ac m ma en not accip t e e to roducethe same shade as the normal textile material the backing material during the .tuftlng operatlon. p I

It is also an Object offllis invention :10 provide a used in the pile yarns. It-lra been determined that both colored coated backing material for tufted carpets which of .P y be larg ly Solved by coating the will harmonize in color with the yarns tuftedin said backfabrlc P 10F to tuftmg: Wlth a latex mammal -Y ing material and which will essentially :resist the distorth desired ng material in solutions dispersionsing stresses occasioned by :the passage Of tufting needles Specific examples of particular compositions which have through the backing material. r a been .found satisfactory for this are listed below:

EXAMPLE #1 Chemical Classification Commercial Product Vendor Formula inPounds Acrylic resin dispersion- Rhoplex ACT-33 Rohm & Haas Sodium polyacrylate thickener (5%) Aerysol GS RohmdzHaas 10 Phthalocyanme Blue Paste m Monastral F. Blue BC Du Pont 5 EXAMPLE #2 Acrylic resin dispersion Rhoplex AC-33 Rohm & Haas 100 Sodium alginate thickener (3%) Keltex Kelco Co 50 Phthalocyanine Blue Paste Monastral F. Blue B Du Pont 5 EXAMPLE #3 Compounded GRS-Rubber Latex Vulcanol 2009 Alco Oil 5: Chemical Oo 100 Sodium alginate thickener (3%) Keltex Kelco O0 30 Phthaloeyanine Blue Paste Monastral F. Blue BC Du Pont; 5

EXAMPLE #4 Chemical Classification Commercial Product Vendor Formula in Pounds Acrylonitrile Polymer Dispersion Nitrex 2614 Naugatuck Chemical Oo 100 Sodium alginate thickener (3%) Keltex Kelco o 50 Vat Dye Color Index #1101 (Dimethoxy Dibenzanthrone) Ponsol Jade Green Double Paste Du Pont 10 EXAMPLE #5 compounded GRS-Rubber Latex Vulcanol 2009 A100 Oil & Chemical Got... 33% Acrylonitrile Polymer Dispersion Nltrex 26l4 N augatuck Chemical Oo 66% Sodium alginate thickener (3%). e te Kelco Co 43% Phthaloeyanine Blue Paste Monastral F. Blue BC 1% Vat Dye Color Index #1101 (Dimethoxy Dibenzanthrone) Ponsol Jade Green Double Paste Du Pont 6% In addition to the above, copolymers of vinyl chloride and vinyl acetate may be used in place of acrylic aciylonitrile, or rubber binders. Compatible mixtures of these binders are also satisfactory. In any event the binder material should not be less than equal in amount to the pigment used and can be present in any amount above that, which will still give a good spreading dispersion. While sodium alginate is set forth as the thickener in these examples any thickener such as carob gum, methyl cellulose and the like which are compatible with the dispersion may be used. Of course, any desirable pigment may be used.

The coating material 13 may be applied to the backing material 10 in any known manner for applying coatings to fabrics. For example, as shown in Fig. 2 the coating 13 may be applied by means of rollers 14, 15 and 16 drawing the material 13 from container 17. It will be noted that it is only necessary to apply the coating 13 to one side of the backing material 10.

When the backing material 10 has been coated the coating material 13 is distributed across the upper surface of the yarns 11 and 12 without substantial filming between parallel strands, but cementing the yarns at the cross-overs. It is, of course, desirable to maintain the meshes of the fabric 10 open as far as possible to avoid placing any additional strain on the tufting needles and the tufting machine.

The coated backing material 10 is then fed in the usual manner through a tufting machine 18 in Which the pile yarns 19 are tufted into backing material 10. Where a sheared pile fabric is desired the loops of the yarns 19 are cut by means of shearing knife 20.

The resulting product shown in Fig. 5 is a tufted pile fabric in which the backing material is provided with a coloring which harmonizes with the coloring of the pile yarns after the pile yarns have been dyed. The pile yarns are dyed the desired color in the usual manner subsequent to shearing. It will be noted, as shown in Fig. 5, that, due to the tufting operation, strands 11 and 12 of backing material 10 and particularly weft strands 11 are distorted in position by the tufting operation. The application of the coated material '13 provides great stability in the backing material 10 tending to resist distortion. The resulting fabric has much greater fabric stability.

As is customary in the art of tufted carpets a binding composition is applied to the back of the backing material 10 to insure the retention of the tufted pile yarns 19 in the backing material 10. Such a binding material is indicated at 21 in Fig. 5.

It will be understood that numerous variations may be made in the steps and elements of the invention without departing from the scope thereof as defined by the following claims.

Having thus described our invention, we claim:

1. A tufted pile fabric comprising a woven backing material, a plurality of colored textile yarns tufted in said backing material, having a specific color producing a specific visual color effect a first colored coating material applied to the upper surface of said backing material having a pigment contained therein producing the same visual color effect as the color in said pile yarns and a second coating material applied to the under side of said backing material to retain said pile yarns in place in said backing material.

2. A method of making a tufted pile carpet comprising the steps of first coating a woven jute backing material on one side with a dispersion of a specific coloring pigment in latex, then tufting a plurality of textile yarns in said backing material, then dyeing said tufted yarns with a dye having a pigment producing the same visual color effect as the pigment of the dye applied to said backing material and then coating the backing material on the side opposite said first coating with a binder material to retain the pile yarns in place.

3. A method of making a tufted pile carpet having tufted yarns dyed with a specific coloring pigment comprising the steps of first coating a woven jute backing material on one side with a dispersion in latex of a coloring pigment producing the same visual color effect as the pigment in the dye of said tufted yarns, then tufting a plurality of said textile yarns dyed with said specific coloring pigment in said backing material and then coating the backing material on the side opposite said first coating with a binder material to retain the pile yarns in place.

References Cited in the file of this patent UNITED STATES PATENTS 2,042,503 Carter June 2, 1936 2,220,589 Unger Nov. 5, 1940 2,261,096 Reinhardt Oct. 28, 1941 2,314,162 Reinhardt Mar. 16, 1943 2,630,620 Rand Mar. 10, 1953 xiv UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,908,013 October 13,.v 1959' William Rollin Keen at a].

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction and that the said Letters Patent should readas corrected below.

Column 1, line 34, for "Dus" read Due Signed and sealed this 19th day of April 1960.

(SEAL) Attest:

ROBERT C. WATSON KARL He- AXLINE Commissioner of Patents Attesting Officer 

